EP2244873A1 - A method for controlling fill speed in a molding system - Google Patents
A method for controlling fill speed in a molding systemInfo
- Publication number
- EP2244873A1 EP2244873A1 EP09713647A EP09713647A EP2244873A1 EP 2244873 A1 EP2244873 A1 EP 2244873A1 EP 09713647 A EP09713647 A EP 09713647A EP 09713647 A EP09713647 A EP 09713647A EP 2244873 A1 EP2244873 A1 EP 2244873A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- cavity
- mold
- filling
- speed
- parameter
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76006—Pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/7604—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76056—Flow rate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/7611—Velocity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76003—Measured parameter
- B29C2945/76167—Presence, absence of objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76177—Location of measurement
- B29C2945/76254—Mould
- B29C2945/76257—Mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76344—Phase or stage of measurement
- B29C2945/76381—Injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76545—Flow rate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76595—Velocity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76655—Location of control
- B29C2945/76658—Injection unit
- B29C2945/76665—Injection unit screw
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76655—Location of control
- B29C2945/76658—Injection unit
- B29C2945/76678—Injection unit injection piston
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76822—Phase or stage of control
- B29C2945/76859—Injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76929—Controlling method
- B29C2945/76939—Using stored or historical data sets
- B29C2945/76943—Using stored or historical data sets compare with thresholds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/53—Means for plasticising or homogenising the moulding material or forcing it into the mould using injection ram or piston
- B29C45/54—Means for plasticising or homogenising the moulding material or forcing it into the mould using injection ram or piston and plasticising screw
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
- B29K2067/04—Polyesters derived from hydroxycarboxylic acids
- B29K2067/046—PLA, i.e. polylactic acid or polylactide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
Definitions
- the present invention generally relates to, but is not limited to, a molding system, and more specifically the present invention relates to, but is not limited to, a stress-reducing device and a method of using same.
- Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system.
- Various molded articles can be formed by using the molding process, such as an injection molding process.
- One example of the molded article that can be formed, for example, from polyethylene terephthalate (PET) material is a preform that is capable of being subsequently blow-molded into a beverage container, such as, a bottle and the like.
- PET polyethylene terephthalate
- Other examples of the molded articles include thin-wall containers (i.e. yogurt containers, cups, etc), medical appliances and the like.
- injection molding of PET material involves heating the PET material (ex. PET pellets, PEN powder, PLA, etc.) to a homogeneous molten state and injecting, under pressure, the so- melted PET material into a molding cavity defined, at least in part, by a female cavity piece and a male core piece mounted respectively on a cavity plate and a core plate of a mold.
- the cavity plate and the core plate are urged together and are held together by clamp force, the clamp force being sufficient to keep the cavity and the core pieces together against the pressure of the injected PET material.
- the molding cavity has a shape that substantially corresponds to a final cold-state shape of the molded article to be molded.
- the so-injected PET material is then cooled to a temperature sufficient to enable ejection of the so-formed molded article from the mold.
- the molded article shrinks inside of the molding cavity and, as such, when the cavity and core plates are urged apart, the molded article tends to remain associated with the core piece.
- the molded article can be ejected off the core piece by use of one or more ejection structures.
- Ejection structures are known to assist in removing the molded articles from the core halves. Examples of the ejection structures include stripper plates, stripper rings and neck rings, ejector pins, etc.
- Preliminary molding is performed to obtain an acceptable product; a total charged amount of resin during the preliminary mold is obtained on the basis of a movement distance over which the screw has moved before reaching the control changeover point during the preliminary mold; and the total charged amount is stored as a changeover target value.
- a total charged amount of resin is obtained on the basis of a movement distance over which the screw advances from the injection start position; and pressure control is started when the total charged amount reaches the changeover target value.
- US patent application bearing a publication number 2005/0053684 published on March 10, 2005 by Pitschebeder et al. discloses an injection molding machine with a mold that can be opened and closed, into the mold cavity of which a fluid molding compound, preferably plastic, can be injected, and with at least one reading device for at least one transponder arranged in the mold cavity.
- a method for controlling a fill speed of an injection unit the method executable in a computing apparatus configured to control a plunger actuator of the injection unit.
- the method comprises receiving an indication of a mold-cavity- filling parameter, the mold-cavity-filling parameter being indicative of a number of molding cavities of a multi-cavity mold having been filled; responsive to the mold-cavity-filling parameter satisfying a pre-determined threshold, releasing a control signal to the plunger actuator to control speed associated with a plunger of the injection unit from a first filling speed to a second filling speed.
- a speed management sub-system for controlling a fill speed of an injection unit.
- the speed management sub-system comprises a sensor associated with a multi-cavity mold, the sensor configured to detect a mold-cavity- filling parameter, the mold-cavity-filling parameter being indicative of a number of molding cavities of the multi-cavity mold having been filled; a computing apparatus operatively coupled to the sensor and to a plunger actuator configured to actuate a plunger of the injection unit, the computing apparatus being configured to receive an indication of the mold-cavity-filling parameter from the sensor; and sensor; and responsive to the mold-cavity-filling parameter meeting a pre-determined threshold, to release a control signal to the plunger actuator to control speed associated with the plunger from a first filling speed to a second filling speed.
- Figure 1 depicts a sectional view of an injection unit 100 implemented according to a non-limiting embodiment of the present invention.
- Figure 2 depicts a perspective view of a melt distribution network 200 implemented according to a non-limiting embodiment of the present invention.
- Figure 3 depicts a flow chart of a non-limiting embodiment of a method for controlling fill speed, the method executable within the injection unit 100 of Figure 1.
- Inventors have developed embodiments of the present invention based on their appreciation of the fact that the problem of rolled threads may be attributed, at least partially, to an imbalanced nature of filling of molding cavities within a multi-cavity mold. More specifically, inventors have appreciated that, in a multi-cavity mold that includes an "unbalanced hot runner" (for example, thermally-unbalanced, rheology-unbalanced and the like), as more and more molding cavities of the multi-cavity mold get filled, the molten material filling rate, the remaining cavities are subjected to, is comparatively high. This, in turn, leads to increased shear rates experienced by the molten material filling the remaining cavities.
- an "unbalanced hot runner" for example, thermally-unbalanced, rheology-unbalanced and the like
- this increased shear rate is particularly prominent (but is not limited to) the neck finish of the preforms. finish of the preforms.
- This leads to increased temperature of the molten material, particularly, in the neck finish area of the preform.
- the neck finish with elevated temperature of the molten material does not have enough time to cool, resulting in the demolding defects typically known as "rolled threads" or, put another way, in a preform having the neck finish smeared during demolding of the preform off a core member.
- an injection unit 100 that can be configured to implement non-limiting embodiments of the present invention.
- the injection unit 100 can be part of an injection molding machine 160, which is only conceptually depicted in Figure 1, but is well known to those skilled in the art.
- the injection molding machine 160 can be configured for manufacturing of various molded articles. Purely as means of an example for illustrating embodiments of the present invention, it shall be assumed that the injection unit 100 is part of the injection molding machine 160 configured for manufacturing of preforms which are suitable for subsequent blow- molding into beverage containers.
- embodiments of the present invention are not so limited and can be equally implemented within context of other type of injection equipment.
- the injection unit 100 can be of a two-stage type and to that extent, the injection unit 100 comprises a barrel 102 and a shooting pot 104.
- the injection unit 100 comprises a barrel 102 and a shooting pot 104.
- a screw 106 which is actuated by a screw actuator 108.
- the screw actuator 108 imparts rotational and reciprocal movements to the screw 106.
- the barrel 102 is associated with a plurality of barrel heaters 105.
- Combination of the rotation of the screw 106 and heat emitted by the plurality of barrel heaters 105 causes molding raw material (such as, for example, PET) fed through an inlet 110 to melt until a desired amount of material at a desired molten state has been produced and accumulated in front of the screw 106.
- the inlet 110 can be provided with a hopper (not depicted) or other suitable flow directing means, which are known to those of skilled in the art.
- the shooting pot 104 includes a plunger 114 which is actuated by a plunger actuator 116.
- the plunger actuator 116 imparts a a lateral movement (or, in other words, forward translation) to the plunger 114, which causes the accumulated desired amount of material to be transferred into a mold (not depicted) via a nozzle 118.
- the injection unit 100 can be of a single stage type or, put another way, of a type known as reciprocating screw injection unit (not depicted).
- the injection unit 100 comprises a plasticizing and injecting screw (not depicted), which serves several functions, including plasticizing and injection.
- the plasticizing and injecting screw combines functions of the screw 106 and the plunger 114.
- the term “plunger” also includes functionality and structure of the plasticizing and injection screw (not depicted) of the reciprocating screw injection unit (not depicted) to the extent it performs injection function.
- the term “plunger actuator” also includes an actuator (not depicted) of the plasticizing and injecting screw (not depicted).
- the plunger actuator 116 is operatively coupled to and is under control of a computing apparatus 130.
- the computing apparatus 130 can be a general purpose or special purpose processing apparatus.
- the computing apparatus 130 can be implemented as part of a controller (not depicted) that controls operation of the injection molding machine 160.
- the computing apparatus 130 can be implemented as a separate processing apparatus in addition to the controller (not depicted) that controls operation of the injection molding machine 160.
- the functionality performed by the computing apparatus 130 can be distributed between one or more processing apparatuses, including (but not limited to) the controller (not depicted) that controls operation of the injection molding machine 160 and another processing apparatus potentially present within or associated with the injection molding machine 160.
- the computing apparatus 130 is configured to implement several control routines that are configured to control operation of the plunger actuator 116.
- Some examples of these control routines include, but are not limited to, starting translation of the plunger 114, stopping translation of the plunger 114, controlling pressure that the plunger 114 exerts onto the molten material, controlling (i.e. changing) speed with which the plunger 114 translates forwardly or backwardly (or, put another way, change filling speed associated therewith) and the like.
- the injection molding machine 160 further includes a multi-cavity mold, which is not depicted but well known to those of skill in the art.
- the multi-cavity mold (not depicted) is configured to form a plurality of molded articles, such as preforms and the like.
- the multi-cavity mold (not depicted) includes a melt distribution network 200 for conveying molding material from the injection unit 100 to a plurality of molding cavities defined within the multi-cavity mold (not depicted).
- a non-limiting embodiment of the melt distribution network 200 is depicted in Figure 2.
- the melt distribution network 200 is typically embedded in one or more plates (not depicted) and sometimes referred to by those of skill in the art as a "hot runner".
- the melt distribution network 200 comprises a melt inlet 202 and a plurality of melt outlets 204.
- the melt inlet 202 is also referred to by those of skill in the art as a "sprue bushing" and is configured to cooperate, in use, with the injection unit 100 to provide a point of entry for the molten material flow into the melt distribution network 200.
- Each of the plurality of melt outlets 204 will be referred to herein below as a melt outlet 104, however, those of skill in the art sometimes also refer to the melt outlet 104 as a "drop".
- Each of the plurality of melt outlets 204 is configured to cooperate, in use, with a molding cavity (not depicted) defined between cooperating mold core (not depicted) and mold cavity (not depicted) to provide a point of exit for the melt from the melt distribution network 200. Even though not visible in Figure 2, each of the plurality of melt outlets 204 defines an internal flow channel (not depicted) for the melt and terminating at an orifice (not separately numbered) of a nozzle tip 222.
- each of the plurality of melt outlets 204 is also associated with a valve stem 220 disposed, at least partially, within the internal flow channel (not depicted).
- the valve stem 220 is actuatable between a closed position and an open position. In the closed position, the valve stem 220 substantially obstructs the orifice (not separately numbered) associated with the nozzle tip 222 to substantially prevent flow of the melt. In the open position, the valve stem 220 substantially un-obstructs the orifice (not separately numbered) associated with the nozzle tip 222 to allow for the melt to flow.
- the valve stem 220 can be actuated by any known actuator, such as piston-type actuators and the like. Ln alternative non- limiting embodiments of the present invention, the nozzle tip 222 can be "thermally gated" and within those embodiments of the present invention, the valve stem 220 (and the associated actuators) can be omitted.
- the melt inlet 202 is fluidly coupled to the plurality of melt outlets 204 via a network of runners 206.
- the network of runners 206 comprises a first level sub-network 208 and a second level sub-network 210.
- the first level subnetwork 208 is fluidly coupled to the melt inlet 202.
- the second level sub-network 210 comprises twelve (12) instances of a second level distributor 216.
- Each of the twelve instances of the second level distributor 216 is coupled to the first level sub-network 208 via a coupler 218.
- the coupler 218 is implemented as a transition bushing, which is implemented as an elongated tubular body.
- the plurality of heater receptacles 224 is configured to accept, in use, a plurality of heaters (not depicted) that is configured to provide heating to maintain a target temperature associated with the melt flowing via the melt distribution network 200.
- a sensor 226 there is provided a sensor 226.
- the sensor 226 may comprise a plurality of sensors 226.
- the sensor 226 can be embodied in any suitable sensor to detect a "mold-cavity-filling parameter".
- the "mold-cavity-filling parameter" is indicative (directly or indirectly) of how many molding cavities (not depicted) of the multi-cavity mold (not depicted) have been filled with the molten material.
- the senor 226 can be implemented in any suitable means that can detect presence of the molten material at a given point in a molding cavity or the melt distribution network 200, which can be then correlated to the number of molding cavities of the multi-cavity mold (not depicted) that have been filled at a given point in a filling portion of a molding cycle.
- Suitable implementation for the sensor 226 include, but are not limited to: (i) a thermocouple for measuring temperature; (ii) a pressure gauge for measuring operating pressure; (iii) a flow measuring device for directly or indirectly measuring the rate of flow past the flow measuring device, (iv) velocity sensor for measuring velocity of the flow and the like. Naturally, other types of the sensor 226 for measuring these or other operating parameters can be used.
- the senor 226 can be associated with a given one of the plurality of melt outlets 204. In other embodiments of the present invention, each of the plurality of sensors 226 can be associated with each respective instance of the melt outlet 204. In yet further embodiments of the present invention, a given one of the plurality of sensors 126 can be associated with a given one of the plurality of melt outlets 204, so selected that only a single instance of the melt outlet 204 per each of the second level distributor 216 is associated with the given one of the plurality of sensors 226. It should be expressly understood that other configurations are also possible.
- the senor 226 can be associated with the molding cavity(ies) of the multi-cavity mold (not depicted). As an example, each instance of the plurality of sensors 226 can be associated with each instance of the molding cavities (not depicted). In other embodiments of the present invention, a given one of the plurality of sensors 226 can be associated with a given one of the molding cavities (not depicted), so selected that a single instance of a molding cavity (not depicted) associated with the plurality of melt outlets 204 per each of the second level distributor 216 is associated with the given one of the plurality of sensors 226.
- the sensor 226 may further comprise an event detector that detects presence of a melt at a particular pre-determined position within the molding cavity, a particular melt characteristic or any other suitable type.
- the event detector can be an on/off switch switchable by the presence of melt or an on/off switch switchable by a particular characteristic associated with the melt (such as melt temperature over a particular threshold, melt pressure over a particular threshold and the like), etc.
- the thermocouple can be positioned in the molding cavity in an area proximate to a neck finish of the preform to be molded.
- detection of a temperature spike by the thermocouple is indicative of the fact that the molten material has reached the neck finish area and, therefore, can be correlated to the fact that the given molding cavity has been filled.
- Similar implementation can be achieved with the pressure gauge, flow measuring device, velocity sensor and event detector.
- the sensor 226 is also configured to communicate with the computing apparatus 130 and, to that extent, the sensor 226 can be coupled either directly to the computing apparatus 130 (ex. via a serial, parallel or coaxial cable connection) or via a communication network (not depicted), such as a Local Area Network, Wide Area Network and the like.
- the communication network (not depicted) can be implemented as a wired communication network, a wireless communication network or the combination of the two.
- the purpose of the sensor 226 is to detect the mold-cavity-filling parameter, the mold-cavity-filling parameter being indicative of how many of the plurality of cavities of the multi-cavity mold (not depicted) have been filled at a given time.
- each of the plurality of sensors 226 detects and transmits a respective mold-cavity-filling parameter to the computing apparatus 130, which collectively form a plurality of mold-cavity-filling parameters.
- the respective mold-cavity-filling parameter denotes whether or not the associated respective molding cavity has been filled. Furthermore, by analyzing the plurality of respective mold-cavity-filling parameters, the computing apparatus 130 can determine how many of the molding cavities of the multi-cavity mold (not depicted) have been filled.
- each of the plurality of sensors 226 detects and transmits a representative mold-cavity-filling parameter (or a plurality of representative mold-cavity-filling parameters) to the computing apparatus 130.
- the computing apparatus 130 can determine how many of the molding cavities of the multi-cavity mold (not depicted) have been filled.
- the internal algorithm can correlate a value of the representative mold-cavity-filling parameter (or the plurality of representative mold-cavity-filling parameters) to the number of the molding cavities of the multi-cavity mold (not depicted) having been filled.
- the sensor 226 can be implemented as a pressure transducer operative to detect a pressure spike.
- the sensor 226 is positionable within the melt distribution network 200.
- the internal algorithm can correlate a pressure spike detected by the sensor 226 to a particular number of molding cavities having been filled.
- a "speed management sub-system" (not separately numbered) for controlling a fill speed of an injection unit (100) is provided.
- the speed management sub-system includes the sensor 226 and the computing apparatus 130.
- a method for controlling a fill speed A non-limiting embodiment of the present invention will now be described in greater detail with reference to Figure 3, which depicts a flow chart of a non-limiting embodiment of a method 300.
- the method 300 can be conveniently executed by the computing apparatus 130.
- Step 302 - receive an indication of a mold-cavity-filling parameter
- the method 300 begins at step 302, where an indication of a mold-cavity-filling parameter is received.
- the computing apparatus 130 is configured to receive an indication of the mold-cavity-filling parameter from the sensor 226.
- the computing apparatus 130 receives a respective or a representative indication of the mold-cavity-filling parameter from each of the plurality of sensors 226, as has been described in greater detail herein above.
- Step 304 - determine if the mold-cavity-filling parameter satisfies a pre-determined threshold
- the computing apparatus 130 is configured to analyze the indication of the mold- cavity-filling parameter received as part of step 302. The purpose of this analysis is to determine whether the number of molding cavities of the multi-cavity mold (not depicted) that have been filled has reached (i.e. satisfies) the pre-determined threshold.
- the computing apparatus 130 can maintain an indication of the predetermined threshold in an internal memory (not depicted). How this indication is populated is not particularly limited and can be, for example, entered by a user (not depicted), hard coded into the internal memory (not depicted), generated by the computing apparatus 130 based on a calculation algorithm and the like.
- the pre-determined threshold can be a particular value, such as 60 per cent of all molding cavities, 70 per cent of all molding cavities, 80 per cent of all molding cavities, 90 per cent of all molding cavities or any other suitable value. It is worthwhile noting that the value for threshold can be expressed as a percentage of molding cavities filled or as an actual number of molding cavities filled.
- the computing apparatus 130 can set an internal counter (not depicted) to zero indicating that there is a single instance of the pre-determined threshold to be used.
- the pre-determined threshold may comprise a plurality of pre-determined thresholds.
- the plurality of pre-determined thresholds may comprise three pre-determined thresholds - a first pre-determined threshold of 65 per cent of all molding cavities, a second pre-determined threshold of 80 per cent of all molding cavities and a third pre-determined threshold of 90 per cent of all molding cavities.
- the number of pre-determined thresholds within the plurality of pre-determined thresholds can vary.
- each of the predetermined thresholds of the plurality of pre-determined threshold may vary, as well as a "step" between any given two of the plurality of pre-determined thresholds can vary and can be either symmetric (i.e. in equal increments) or asymmetric (i.e. in non-equal increments).
- the computing apparatus 130 first compares the received mold-cavity-filling parameter with the first pre-determined threshold. Within these embodiments of the present invention, once the comparison with the first pre-determined parameter is completed, the computing apparatus 130 further sets the internal counter (not depicted) to two, which in this case is a value representative of the second pre-determined threshold and the third predetermined threshold remaining available for comparison, as will be explained in greater detail herein below.
- the computing apparatus 130 compares the so-received single mold-cavity-filling parameter with the pre-determined threshold (or the first pre-determined threshold in case of the plurality of pre-determined thresholds).
- the computing apparatus 130 can compute an average (or a mean or a median) value of the respective or of the representative indication of the mold-cavity-filling parameter and compare the so-computed average (or mean or median) value with the pre-determined threshold.
- the computing apparatus 130 can compare each of the received respective or representative mold-cavity-filling parameter with the pre-determined threshold and then compute how many of the received respective or representative mold-cavity-filling parameters meet or exceed the threshold. If the number of respective or representative mold-cavity-filling parameters that meet or exceed the pre-determined threshold meets or exceeds a pre-determined validation parameter, the computing apparatus 130 may conclude that the pre-determined threshold is satisfied.
- step 304 If the analysis renders a negative outcome or, in other words, the mold-cavity-filling parameter does not satisfy the pre-determined threshold (or the first pre-determined threshold in case of the plurality of pre-determined thresholds), i.e. the "NO" branch of step 304, the method 300 loops back to execution execution of step 302 where it awaits receipt of another indication of the mold-cavity-filling parameter.
- step 304 If, however, the analysis renders a positive outcome or, in other words, the mold-cavity-filling parameter satisfies the pre-determined threshold (or the first pre-determined threshold in case of the plurality of pre-determined thresholds), i.e. the "YES" branch of step 304, the method 300 proceeds to step 306.
- Step 306 responsive to the mold-cavity-filling parameter satisfying the pre-determined threshold, release a control signal to the plunger actuator 116 to control speed associated with a plunger 114 from a first filling speed to a second filling speed
- the computing apparatus 130 is further configured to release a control signal to the plunger actuator 116 to control speed associated with the plunger 114 from the first filling speed to the second filling speed.
- the control signal can be instrumental in causing the plunger actuator 116 to decrease the speed associated with the plunger 114 from the first filling speed to the second filling speed. How the computing apparatus 130 generates such the control signal is well known to those skilled in the art and, as such, will not be discussed here at any length.
- the computing apparatus 130 can further maintain an internal mapping (not depicted) that maps a given pre-determined threshold and a value of the speed to which the plunger actuator 116 should be controlled.
- the control signal can be indicative of the speed retrieved from the internal mapping (not depicted) and be instrumental in causing the plunger actuator 116 to change the speed of the plunger 114 to the speed which indication is maintained within the control signal (i.e. to the second filling speed).
- the computing apparatus 130 is configured to determine whether the internal counter (not depicted) is set to zero, which is indicative of either (i) a single pre-determined threshold having been set or (ii) the last one of the plurality of pre-determined thresholds having been compared with the mold-cavity- filling parameter.
- the method 300 terminates. It is worthwhile noting, however, that execution of the method 300 can resume from step 302 at a next molding cycle.
- the method 300 loops back to executing the step 302, where it awaits receipt of another indication of the mold-cavity- filling parameter.
- the first instance of receiving the indication of the mold-cavity-filling parameter can be considered to be receiving a first indication of the mold-cavity-filling parameter indicative of the mold filling parameter at a first instance in time and a subsequent receiving of the indication of the mold-cavity- filling parameter can be considered to be receiving a subsequent indication (ex.
- the control signal generated by the computing apparatus 130 can be thought of as a first control signal, a second control signal, etc depending at which round of execution of the method 300 it is generated.
- step 304 when the computing apparatus 130 determines, as part of step 304, that the second indication of the mold-cavity-filling parameter satisfies the second pre-determined threshold, the computing apparatus 130 can set the internal counter (not depicted) to one. The computing apparatus 130 then releases a second control signal that is configured to change the speed of the plunger 114 from the second filling speed to a third filling speed.
- the computing apparatus 130 determines, as part of step 304, that the third indication of the mold-cavity-filling parameter satisfies the third pre-determined threshold, the computing apparatus 130 can set the internal counter (not depicted) to zero. The computing apparatus 130 then releases a third control signal that is configured to change the speed of the plunger 114 from the third filling speed to a fourth filling speed or, alternatively, to a hold state at which points it is pressure controlled.
- the method 300 can be executed during a filling stage of a molding cycle or, more particularly, the method 300 can be executed in real-time during each molding cycle of the injection molding machine 160.
- the method 300 can be used to update / correct a filling speed profile maintained in the computing apparatus 130 and such may not need to be repeated each and every molding cycle.
- the method 300 can be executed at a first instance in time to generate and/or update the filling speed profile, while the injection molding machine 160 is run at a second instance of time (i.e.
- the method 300 can be additionally executed during running of the injection molding machine 160 to determine whether the filling speed profile needs to be updated / revised in real time.
- a technical effect of embodiments of the present invention may include provision of the injection unit 100 that provides for more even fill speed experienced by the molten material filling the molding cavities (not depicted) in the multi-cavity mold (not depicted).
- Another technical effect of embodiments of the present invention may include at least decreased occurrence of demolding defects, such as rolled threads. It should be noted that not each and every technical effect, in its entirety, needs to be enjoyed in each and every embodiment of the present invention.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/033,116 US7736555B2 (en) | 2008-02-19 | 2008-02-19 | Method for controlling fill speed in a molding system |
PCT/CA2009/000100 WO2009103147A1 (en) | 2008-02-19 | 2009-01-30 | A method for controlling fill speed in a molding system |
Publications (3)
Publication Number | Publication Date |
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EP2244873A1 true EP2244873A1 (en) | 2010-11-03 |
EP2244873A4 EP2244873A4 (en) | 2011-10-12 |
EP2244873B1 EP2244873B1 (en) | 2013-07-10 |
Family
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Application Number | Title | Priority Date | Filing Date |
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EP09713647.7A Not-in-force EP2244873B1 (en) | 2008-02-19 | 2009-01-30 | A method for controlling fill speed in a molding system |
Country Status (5)
Country | Link |
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US (1) | US7736555B2 (en) |
EP (1) | EP2244873B1 (en) |
CN (1) | CN101952103B (en) |
CA (1) | CA2712419C (en) |
WO (1) | WO2009103147A1 (en) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011081694A1 (en) | 2009-12-31 | 2011-07-07 | Husky Injection Molding Systems Ltd. | Mold-runner system having independently controllable shooting-pot assemblies |
US10684603B2 (en) | 2015-01-13 | 2020-06-16 | Bucknell University | Dynamically controlled screw-driven extrusion |
CN104772881B (en) * | 2015-04-15 | 2017-04-19 | 合兴集团有限公司 | Method and device for adjusting runner balance of multi-cavity mold |
CA3002728A1 (en) * | 2015-11-11 | 2017-05-18 | Husky Injection Molding Systems Ltd. | Shooting pot refill control |
EP3374146B1 (en) * | 2015-11-11 | 2020-10-07 | Husky Injection Molding Systems Ltd. | Shooting pot plunger control |
CN113001873B (en) * | 2021-03-10 | 2022-12-23 | 李建华 | Road cone rotary type continuous preparation method |
CN113065039A (en) * | 2021-03-30 | 2021-07-02 | 南通鼎鑫电池有限公司 | Heap removes energy storage system of family |
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JP2005007639A (en) * | 2003-06-17 | 2005-01-13 | Japan Steel Works Ltd:The | Method for controlling moving speed of screw of electromotive injection molding machine |
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JP2001179786A (en) | 1999-12-27 | 2001-07-03 | Kanto Auto Works Ltd | Injection molding machine having multipoint gate |
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- 2009-01-30 CA CA2712419A patent/CA2712419C/en not_active Expired - Fee Related
- 2009-01-30 CN CN2009801051402A patent/CN101952103B/en not_active Expired - Fee Related
- 2009-01-30 WO PCT/CA2009/000100 patent/WO2009103147A1/en active Application Filing
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Also Published As
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CA2712419C (en) | 2012-09-04 |
CN101952103A (en) | 2011-01-19 |
CA2712419A1 (en) | 2009-08-27 |
WO2009103147A1 (en) | 2009-08-27 |
CN101952103B (en) | 2013-11-13 |
EP2244873A4 (en) | 2011-10-12 |
US7736555B2 (en) | 2010-06-15 |
US20090206501A1 (en) | 2009-08-20 |
EP2244873B1 (en) | 2013-07-10 |
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